Die Cutting and Custom Shapes
Die cutting is what makes a printed product a custom shape. Instead of the standard rectangle that comes off the press, a die cut product is cut to any shape you need. A business card with rounded corners, a label that follows the contour of a bottle, a menu shaped like a cocktail glass, packaging that folds into a box. All of it starts with a die.
This guide explains how die cutting works, when each method is the right choice, and how our existing die library can often save you a significant amount on your first job.
WHAT IS DIE CUTTING
What it is Die cutting uses a sharp steel blade formed into the shape of the required cut and pressed through the printed stock under pressure. The result is a clean, precise cut edge that follows the exact profile of the die. The die can be any shape, simple or complex, geometric or organic.
What it produces A printed product cut to a custom shape with a clean edge. The shape is consistent across every piece in the run because every cut uses the same die. Die cutting can cut through the stock entirely, or kiss cut where the blade cuts through the face of the stock but not the backing, leaving labels and stickers easy to peel.
TRADITIONAL DIE CUTTING
What it is A steel rule die is custom made for your shape. Sharp steel blades are bent and set into a wooden board in the exact profile of the required cut. The die is mounted in a press and the printed stock is fed through under pressure, cutting the shape cleanly and consistently.
Best for Production runs where the same shape is being cut across a large quantity. Traditional die cutting produces the cleanest, most consistent cut edge available and is the right choice for any job where quality and precision matter. Business cards, labels, packaging, menus, wobblers, hang sells, strut cards, neck tags, coasters, swing tags, gift card carriers, and any other product that needs a precise custom shape.
Cost The cost of the die is included in your first job quote. There is no separate setup invoice. When you reorder the same shape the die cost does not apply again, so repeat jobs cost less than the first run.
One thing worth knowing Once a die is made we hold it on file for all future reorders. Repeat jobs using the same die cost less than the first run because the die is already made. For any product you plan to reorder regularly it is worth knowing that the first run is the most expensive and it gets more cost effective from there.
WHEN TO USE EACH
| Digital Die Cutting | Traditional Die Cutting | |
|---|---|---|
| Best for | Prototypes, samples, shape testing | Production runs, quality-critical work |
| Die cost | None | Included in first job, free on reorders |
| Edge quality | Good | Excellent |
| Shape changes | Easy, no cost | Requires a new die |
| Short runs | Yes, higher per unit cost | Yes, once die exists, lower per unit cost |
| Long runs | Not suitable | Yes, most cost effective |
OUR EXISTING DIE LIBRARY
Over decades of production we have built up a large library of existing steel rule dies across all product categories. Business cards, labels, packaging, POS products, menus, coasters, swing tags, and more.
Before we quote a new die we always check the library first. More often than not we have a shape that is close to what you need. A small adjustment of a few millimetres to your artwork can often mean your shape fits an existing die exactly, saving you the die cost on your first job.
It is always worth getting in touch and sending us your artwork before assuming you need a new die. We have decades of dies in our library and the chances are good that something in there works for your brief.